KR100747930B1 - Holding and sealing member and exhaust emission control device - Google Patents

Abstract

An object of the present invention is to improve the sealing property and the holding force of a holding sealer for holding an exhaust gas treating body used in an exhaust gas purifying apparatus in a metal cell.

In the present invention, the holding sealer for holding the exhaust gas treating body used in the exhaust gas purifying apparatus has a first surface and a second surface, is composed of a sheet material made of inorganic fibers, and the uneven height of the second surface is the first. It is characterized by being lower than the uneven | corrugated height of a surface. The holding seal member having such a feature is wound and fixed so that the second surface is in contact with the outer circumferential surface of the exhaust gas treating body. Thereby, the "wrinkle" which arises from the difference in the peripheral length of the inner periphery and the outer periphery of a holding sealing material is reduced, and the exhaust gas purification apparatus excellent in gas sealing property and holding property can be obtained.

Description

HOLDING AND SEALING MEMBER AND EXHAUST EMISSION CONTROL DEVICE}

1A is a view showing an example of a sheet member used for the holding seal member of the present invention;

1B is a configuration diagram when the holding sealing material according to the present invention is wound around and fixed to an exhaust gas treating body and pressed into a metal cell to form an exhaust gas treating apparatus;

2A is a cross-sectional view taken along the line A-A of the sheet member of FIG. 1A;

2B is a conceptual diagram showing the effect of the holding sealing material according to the present invention;

3A is a conceptual diagram showing a state when a conventional holding seal material is integrated with an exhaust gas treating body and attached to a metal cell;

3B is a conceptual diagram showing a state when the holding sealer according to the present invention is integrated with an exhaust gas treating body and attached to a metal cell;

4 is a diagram showing one configuration example of an exhaust gas purification device of the present invention;

Fig. 5A is a photograph showing the shape of the first surface of the sheet member of the first embodiment according to the present invention;

Fig. 5B is a photograph showing the shape of the second surface of the sheet member of the first embodiment according to the present invention;

FIG. 6 is a graph showing the relationship between the uneven height ratio of the first and second surfaces and the pull-out load; FIG.

7 is a graph showing the relationship between the average diameter of a fiber and the drawn load.

Explanation of symbols on the main parts of the drawings

1: introduction pipe 4: exhaust pipe

6: first surface 8: second surface

10: exhaust gas purification device 12: metal cell

14: inside of the holding seal member 15: holding sealing member

16: outer side of holding seal material 18: corrugation

20: exhaust gas treatment body 24: sheet material

26 surface 150 fitting convex portion

160: fitting recess

The present invention relates, in particular, to an exhaust gas purifying apparatus comprising a holding sealing material and a holding sealing material used in an exhaust gas purifying apparatus and the like.

The number of automobiles has increased dramatically in the current century, and in proportion to this, the amount of exhaust gas emitted from the internal combustion engine of automobiles has also increased rapidly. In particular, various substances contained in the exhaust gas of diesel engines cause pollution, and have a serious impact on the global environment at present.

Under these circumstances, various exhaust gas purification apparatuses have been proposed and put into practical use. A general exhaust gas purifier has a structure in which a casing (metal cell) is provided in the middle of an exhaust pipe connected to an exhaust gas manifold of an engine, and an exhaust gas processing body having a plurality of fine holes is disposed therein. Examples of the exhaust gas treating body include a catalyst carrier and a diesel particulate filter (DPF). For example, in the case of DPF, according to the above-described structure, when the exhaust gas passes through the exhaust gas treating body, the fine particles are trapped in the peripheral wall of the hole, so that the fine particles can be removed from the exhaust gas. The structural material of the exhaust gas treating body includes ceramics in addition to metals and alloys. As a representative example of an exhaust gas treating body made of ceramic, a cordierite honeycomb filter is known. In recent years, in view of heat resistance, mechanical strength, chemical stability, and the like, a porous silicon carbide sintered body has been used as a material for the exhaust gas treating body.

A holding sealer is usually provided between the exhaust gas treatment body and the metal cell. The holding seal member is used to prevent damage caused by the contact between the exhaust gas treating body and the metal cell while driving the vehicle, and to prevent the exhaust gas from leaking from the gap between the metal cell and the exhaust gas treating body. In addition, the holding sealer serves to prevent the exhaust gas treating body from falling off due to the exhaust pressure of the exhaust gas. In addition, the exhaust gas treating body needs to be maintained at a high temperature in order to maintain reactivity, and the holding sealer also requires heat insulating performance. As a member that satisfies these requirements, there is a sheet member made of inorganic fibers such as alumina fibers.

The sheet member is wound around at least a part of the outer circumferential surface except for the opening face of the exhaust gas treating body, and is fixed integrally with the exhaust gas treating body by taping or the like, thereby functioning as a holding sealing material. Thereafter, this integrated product is pressed into the metal cell and attached to the exhaust gas purifying apparatus.

In addition, sheet materials made of inorganic fibers are bulky, and various methods have been proposed to improve the adhesion of the holding and sealing materials to the metal cells. For example, the technique which makes thin the sheet thickness by impregnating and apply | coating an organic binder to the laminated sheet of an inorganic fiber is proposed (refer patent document 1). Further, the laminated sheet made of inorganic fibers is subjected to a treatment called needling and the like, and the inorganic fibers are entangled with each other in the thickness direction of the sheet, thereby compressing the bulky laminated sheet, thereby reducing the thickness of the sheet material. The method is proposed (refer patent document 2).

[Patent Document 1] Japanese Patent Application Publication No. 59 (1984) -126023

[Patent Document 2] Japanese Patent Application Laid-Open No. 11 (1999) -22013

However, in the conventional method, when the sheet material is used as the holding seal material, and wound around the cylindrical exhaust gas processing body, for example, the inner surface side (the exhaust gas processing body 20 side) and the outer surface side (metal cell ( The "crease" 18 caused by the difference in the circumferential length of the side 12) is generated on the inner surface side of the holding sealing material (see Fig. 3A). Such wrinkles 18 not only cause a drop in sealing performance due to leakage of exhaust gas from the holding sealer (sheet material), but also when the exhaust gas treating body and the holding sealer are integrally attached to the metal cell, The part is susceptible to local stress concentrations, and the holding seal material is likely to break at this location. In this case, the above-described function of the holding seal member is impaired, and dropping or damage of the exhaust gas treating body may occur.

Also, in recent years, the fiber diameter of the inorganic fibers contained in the sheet member tends to increase in consideration of the health of the worker to be attached. For example, it is expected that the average particle diameter of the inorganic fiber will change from the maximum of 6 µm to 7 µm or more in the future. Therefore, the problem of the bulkiness of the sheet material and the wrinkle problem of the holding and sealing material occurring when the sheet material is wound is inherently more serious as the fiber diameter increases.

The present invention has been made in view of the above problems, and provides a holding seal member that is excellent in adhesion to an exhaust gas treating body and excellent in gas sealing property and holding property to the exhaust gas treating body, or such a holding seal. An object of the present invention is to provide an exhaust gas purification apparatus having ashes.

The holding sealing material of the present invention is a holding sealing material for holding an exhaust gas treating body, wherein the holding sealing material has a first surface and a second surface, and is composed of a sheet material made of inorganic fibers, and the uneven height of the first surface. Is higher than the height of the unevenness of the second surface.

As shown in FIG. 1A and FIG. 2A which is a sectional view along the A-A line, the 1st surface 6 of a sheet | seat material has the high uneven | corrugated height compared with the 2nd surface 8. For this reason, as shown in FIG. 1B, the holding sealing material 15 is wound around at least a part of the outer circumferential surface except for the opening surface of the exhaust gas treating body 20, and the fitting protrusion 150 is fitted with the fitting concave portion ( When it is inserted into the metal cell 12 and fixed in the metal cell 12, as shown in FIG. 2B, the rate of elongation of the outer circumferential side 16 of the holding seal member 15 becomes large. The uneven | corrugated height becomes an elongation value, and wrinkles do not generate | occur | produce, and the holding sealing material can be brought into close contact with the outer periphery of the exhaust gas processing body 20. As a result, when sealed in the metal cell 20, the gas sealing property of the holding | maintenance sealing material 15 and the holding property with respect to the waste gas processing body improve.

It is preferable that the said sheet member is comprised by needling the laminated sheet of inorganic fiber, and is comprised. This is because the needling causes fibers to be woven in the thickness direction of the sheet material, thereby increasing the sheet material density to ensure high surface pressure and thinning the thickness below a certain level.

Moreover, it is preferable that the said sheet | seat material has a binder material. This is because the inclusion of the binding material prevents the fibers from scattering when the fibers are bonded to each other and the sealing sealant is enclosed in the metal cell. As the binder, an organic binder or an inorganic binder can be used. Epoxy resins, acrylic resins, rubber resins, styrene resins, and the like may be used as the organic binder, and silica sol, alumina sol, and the like may be used as the inorganic binder. Since the resin is decomposed and removed by the heat of the exhaust gas, the surface pressure of the sheet member is increased, and as a result, the retaining property can be improved. Therefore, it is preferable to use an organic binder.

Moreover, in the sheet | seat material which comprises the said holding sealing material, it is preferable that the uneven | corrugated height of a 1st surface is 1.2-56.7 times of the uneven | corrugated height of a 2nd surface. Thereby, the sealing property as a holding sealing material improves further.

In addition, it is preferable that the average diameter of the said inorganic fiber which comprises the said sheet | seat material is 6 micrometers or more. When the average diameter of the inorganic fibers is less than 6 µm, when the sheet member is wound on the exhaust gas treating body, wrinkles are generated in the sheet member and the drawing load is extremely reduced, but wrinkles are generated by adopting the present invention. It has a remarkable effect that it can prevent the problem of lowering the pulling load by preventing the.

Moreover, it is preferable that the said inorganic fiber which comprises the said sheet | seat material is a mixture of alumina and a silica. As a result, the thermal insulation performance is improved.

The exhaust gas treating body may be a catalyst carrier or an exhaust gas filter.

In addition, the exhaust gas purifying apparatus of the present invention is a holding and sealing material which is wound around at least a part of an outer circumferential surface of the exhaust gas treatment body, a metal cell accommodating the exhaust gas treatment body, and an opening surface of the exhaust gas treatment body. An exhaust gas purification device comprising: a holding material comprising a sheet material having a first surface and a second surface, wherein the holding seal material is made of inorganic fibers, and the uneven height of the second surface of the sheet material is lower than the uneven height of the first surface; And the second surface of the sheet member is wound and fixed to contact the outer circumferential surface of the exhaust gas treating body.

Since the exhaust gas purifying apparatus of the present invention employs a holding seal material with high sealing property and holding force as described above, even if the pressure loss of the exhaust gas processing body increases, the exhaust gas leaks or the pressurization of the exhaust gas is prevented. Since the exhaust gas treating body does not come out of the metal cell, the replacement time of the exhaust gas treating body can be extended, and the life of the apparatus can be extended and the high durability can be ensured.

The apparatus of this invention is shown to FIG. 3B. The holding sealer 15 is in close contact with the outer circumference of the exhaust gas treating body within the metal cell 12 to seal the gap between the metal cell 12 and the exhaust gas treating body 20.

Here, the sheet | seat material which comprises the said holding sealing material may have each characteristic mentioned above. The exhaust gas treatment member may be a catalyst carrier or an exhaust gas filter. In this case, an exhaust gas purifying apparatus excellent in gas sealing properties and retention of the catalyst carrier or the exhaust gas filter is provided.

Embodiment

EMBODIMENT OF THE INVENTION Hereinafter, the best form for implementing this invention is demonstrated with drawing.

In the present invention, the holding sealing material for holding the exhaust gas treating body used in the exhaust gas purifying apparatus has a first surface and a second surface, and is composed of a sheet material made of inorganic fibers, and the uneven height of the first surface is increased. It is higher than the uneven | corrugated height of a 2nd surface, It is characterized by the above-mentioned. The holding seal member having such characteristics is wound and fixed so that the second surface is in contact with the outer circumferential surface of the exhaust gas treating body.

Here, the uneven | corrugated height of the surface of the sheet | seat material 24 was determined as follows. That is, a photograph with a magnification of 12 times is taken at an arbitrary place of the cross section of the sheet member 24, and the difference between the position of the maximum peak of the photograph and the position of the minimum base groove of the photograph is taken as the uneven height. Five photographs were taken and the same measurement was performed, and the average was defined as the uneven height.

In the sheet member 24 constituting the holding seal member 15 of the present invention, the uneven height of the first surface and the uneven height of the second surface are different. Therefore, the surface (first surface 6) with high uneven | corrugated height becomes the outer side (metal cell 12 side) 16 of a holding sealing material, and the surface (second surface 8) with low uneven | corrugated height is holding seal. The sheet material 24 is wound around the outer circumference of the exhaust gas treating body 20 so as to be the inner side (the exhaust gas treating body 20 side) 14 of the ash, and the inner side 14 is usually formed by the difference between the outer circumference and the inner circumference. The occurrence of wrinkles 18 in () is suppressed (see FIG. 3B). When the unevenness of the first surface of the sheet member 24 is wound around the exhaust gas treating body 20, it functions as a compensation for elongation, and the difference in the circumferential length between the inner side 14 and the outer side 16 of the holding seal member 15 is obtained. To mitigate the impact of Thereby, the gas sealing property of the holding sealing material 15 of the waste gas processing apparatus 10 improves. In addition, since pressurization of the holding sealer 15 caused by the wrinkle 18 as a starting point of stress concentration is suppressed, the holding force of the holding sealer 15 holding the exhaust gas treating body 20 is maintained for a long time. .

Here, in the sheet | seat material 24, it is preferable that the uneven | corrugated height of a 1st surface exists in the range of 1.2-56.7 times of the uneven | corrugated height of a 2nd surface. It is because the holding force with respect to the waste gas processing body 20 of the holding sealing material 15 further improves, as mentioned later, when the uneven | corrugated height of both surfaces of the sheet | seat material 24 is controlled. In addition, when the uneven | corrugated height of the 1st surface of the sheet | seat material 24 exceeds 56.7 times the uneven | corrugated height of a 2nd surface, this time an outer surface when the holding sealing material 15 is wound up by the exhaust gas processing body 20 Wrinkles arise in the side, and the sealing property of the holding sealing material 15 falls. Moreover, when the said magnification is less than 1.2, the effect of this invention cannot fully be acquired. Furthermore, it is more preferable that the uneven | corrugated height of the 1st surface of the holding sealing material 15 is 1.2-28.3 of the uneven | corrugated height of a 2nd surface. In this case, the number of wrinkles 18 formed in the holding sealer 15 is further suppressed, and the holding force for the exhaust gas treating body 20 is further improved. In addition, the optimum range of the uneven | corrugated height ratio of both surfaces can also change according to the relationship between the diameter of the object side to be wound, and the thickness of the holding seal material 15. However, if the radius of the exhaust gas treating body 20 on the target side to be wound is usually increased, the thickness of the holding sealing material also becomes thick in proportion thereto. Therefore, even if the diameter of the exhaust gas treating body 20 changes, the optimum range (1.2 to 56.7 times) of the uneven height ratio (the uneven height of the first surface / the uneven height of the second surface) of the first surface and the second surface is varied. ) Can be thought of as little change.

An example of the exhaust gas purification apparatus 10 comprised by such the holding sealing material 15 is shown in FIG. In this figure, the exhaust gas treating body 20 is shown as a catalyst carrier having a through hole, but the exhaust gas purifying apparatus 10 of the present invention is not limited to this configuration. For example, the exhaust gas treating body 20 may be a DPF in which a part of the through hole is blocked. By using the above-mentioned holding seal material for such an exhaust gas purification device, the gas sealing property and the holding property with respect to the waste gas processing body 20 can be improved.

Here, it is preferable that the maximum value of the uneven | corrugated height of the both surfaces of the sheet | seat material 24 is half or less of the thickness of the sheet | seat material 24. This is because if the value is exceeded, the fiber may be damaged when the uneven height of the surface of the sheet member 24 is controlled in the compression drying step described later.

Hereinafter, an example of the manufacturing method of the holding sealing material 15 of this invention is demonstrated.

The holding seal member 15 of the present invention is made of a sheet member 24, and the sheet member 24 can be manufactured as follows.

First, a laminated sheet made of inorganic fibers is produced. In addition, in the following description, although the mixture of alumina and silica is used as an inorganic fiber, an inorganic fiber material is not limited to this, For example, you may comprise only alumina or a silica. A silica sol is added to a basic aluminum chloride aqueous solution having an aluminum content of 70 g / l and Al / Cl = 1.8 (atomic ratio) such that the alumina-silica composition ratio is 60 to 80:40 to 20, thereby preparing a precursor of an inorganic fiber. . It is especially preferable that the alumina-silica composition ratio is about 70-74: 30-26. If the alumina composition ratio is 60% or less, since the composition ratio of mullite produced from alumina and silica is lowered, the thermal conductivity of the sheet member 24 becomes high and sufficient heat insulating performance is not obtained.

Next, an organic polymer such as polyvinyl alcohol is added to the precursor of the alumina fiber. Thereafter, this liquid is concentrated to prepare a spinning liquid. In addition, this spinning solution is used to spin by blowing.

The blowing method is a method of spinning by the air flow blown out of the air nozzle and the spinning liquid flow extruded from the spinning liquid supply nozzle. The flow velocity near the slit from the air nozzle is usually 40 to 200 m / s. The diameter of the spinning nozzle is usually 0.1 to 0.5 mm, and the liquid amount per spinning spinning supply nozzle is usually about 1 to 120 ml / h, but preferably about 3 to 50 ml / h. Under these conditions, the spinning liquid extruded from the spinning liquid supply nozzle does not become a spray (fog) and is sufficiently drawn so that the fibers are hard to weld to each other. A narrow and uniform alumina fiber precursor can be obtained.

Here, it is preferable that it is 250 micrometers or more, and, as for the average fiber length of the alumina type fiber manufactured, it is more preferable that it is 500 micrometers or more. This is because when the average fiber length is less than 250 µm, the fibers are not sufficiently entangled and sufficient strength cannot be obtained. In addition, the average diameter of the inorganic fibers is not particularly limited. It should be noted, however, that the present invention has an effect even if the average diameter of the inorganic fibers is 7 µm or more.

A laminated sheet is manufactured by laminating the precursors having completed spinning. In addition, a needling process is performed on the laminated sheet. The needling process means that the needle is removed from the laminated sheet and the thickness of the sheet is reduced. A needling device is usually used for the needling process. The needling device is usually composed of a needle board that can be reciprocated in the sticking direction and a pair of support plates provided on both sides of the laminated sheet. On the needle board, many needles for sticking to a laminated sheet are fixed at a density of about 100 to 5000/100 cm 2, for example. Further, a through hole for a needle is formed in the support plate. Using such a needling device, a needle is removed from the laminated sheet and subjected to a needling process, whereby the entangled fibers are oriented in the stacking direction, and the stacking direction of the stacked sheet can be strengthened.

The sheet member 24 having a predetermined weight is heated by heating the laminated sheet (hereinafter referred to as the sheet member 24) subjected to this needling treatment at room temperature and continuously burning at a maximum temperature of about 1250 ° C. ) Can be obtained.

For ease of handling, the sheet member 24 thus obtained is cut into predetermined dimensions.

Next, the cut sheet material 24 is preferably impregnated with an organic binder such as resin. Thereby, the bulkiness of the sheet | seat material 24 can be suppressed, and the adhesiveness at the time of using the sheet | seat material 24 as the holding sealing material 15 of the waste gas processing body 20 of the waste gas purification apparatus 10 is carried out. Because it is improved. In addition, it is possible to prevent the inorganic fibers from falling off from the sheet member 24 and the holding force to decrease. In addition, when a high temperature exhaust gas is introduced into the exhaust gas purification device 10, since the organic binder of the holding seal member 15 is lost, the compressed holding seal member 15 is restored, and the metal cell and exhaust gas are exhausted. A small gap that may exist between the gas treating bodies 20 is also blocked, thereby improving the holding force and sealing property of the holding sheet material.

It is preferable that content of an organic type binder is 1.0-10.0 weight%. This is because when the amount is less than 1.0% by weight, the separation of the inorganic fibers cannot be prevented sufficiently. When the amount is more than 10.0% by weight, flexibility is not obtained, and it is difficult to wind the sheet member 24 on the exhaust gas treating body 20.

As the organic binder, for example, acrylic (ACM), acrylonitrile-butadiene rubber (NBR), styrene-butadiene rubber (SBR) resin or the like is preferably used.

The resin is impregnated into the sheet member 24 by spray coating using a water dispersion prepared with such an organic binder and water. In addition, excess adhesion solid content and moisture contained in the sheet | seat material 24 are removed in the next process.

Next, excess solid content is removed and a drying process is performed. Removal of excess solids is carried out by suction and removal of excess water is carried out by heat compression drying. In this method, as described later, the excess moisture is removed, and the pressing force is applied to the sheet member 24 or the sheet member 24 is compressed by using the uneven pattern of various shapes, thereby utilizing the adhesive force of the organic binder. A predetermined uneven height can be formed on both surfaces of the sheet member 24. Drying is performed at the temperature of about 95-155 degreeC. If the temperature is lower than 95 ℃, the drying time is long and the production efficiency is lowered. In addition, at a drying temperature exceeding 155 ° C, decomposition of the organic binder itself is initiated and the adhesion by the organic binder is impaired.

This uneven | corrugated formation process may be performed before the cutting process of a sheet | seat material.

In the drying process, the upper and lower jig for sandwiching the sheet member 24 between the upper and lower jigs is set at a predetermined ratio so that the upper and lower jig of the upper and lower patterns have a predetermined ratio. The uneven | corrugated height of both surfaces can be controlled to become the above-mentioned range. Finally, the sheet member 24 of a predetermined shape can be obtained by cutting.

In this way, a sheet member 24 made of alumina fibers, impregnated with an organic binder and controlled to have uneven heights on both surfaces can be obtained. An example of the sheet | seat material 24 is shown to FIG. 1A. In this figure, although the sheet | seat material 24 is shown so that it may have a set of fitting convex part 150 and the fitting recessed part 160 in the both end surface perpendicular | vertical to a winding direction, the sheet | seat material of this invention ( It is clear that 24 is not limited to this shape. In addition, although the unevenness | corrugation of the 1st surface 6 is shown in the figure so that the waveform of a certain period may spread uniformly over all surfaces, the unevenness | corrugation shape of a surface is not limited to this, The unevenness | corrugation of a 1st surface and a 2nd surface is shown. If the height is in the relation described above, the surface of the sheet member 24 may have any irregularities.

Such a sheet member 24 is used as the holding seal member 15 of the exhaust gas treating body 20 of the exhaust gas purifying apparatus 10. In this case, the sheet material 24 is wound around the exhaust gas processing body 20 so that the surface (second surface) of the uneven height of the sheet material 24 is small (inside of the exhaust gas processing body 20 side). (FIG. 2B). At this time, the sheet member 24 is wound around the exhaust gas treating body 20 so that a certain amount of tension is generated in the winding direction. As a result, the peripheral length difference between the inner side 14 and the outer side 16 of the holding seal member 15 is eliminated, and the occurrence of wrinkles 18 in the inner side 14 is suppressed. Therefore, the sealing property and the holding force of the holding sealing material 15 are improved.

In addition, by using the holding sealer 15 as such, the exhaust gas purification device 10 can be constituted, whereby the exhaust gas purification device 10 excellent in sealing property and holding power can be obtained.

Hereinafter, the effect of this invention is demonstrated by an Example.

(Example)

The sheet member 24 was produced in the following order.

[Production of sheet material]

To a basic aluminum chloride solution having an aluminum content of 70 g / l and Al / Cl = 1.8 (atomic ratio), a silica sol was mixed so that the composition of the alumina fiber was Al ₂ O ₃ : SiO ₂ = 72: 28 to obtain an alumina fiber. A precursor was formed.

Next, an organic polymer such as polyvinyl alcohol was added to the precursor of the alumina fiber. In addition, this solution was concentrated to a spinning solution, and the spinning solution was spun by a blowing method.

Thereafter, the folded sheets of the alumina fibers were laminated to prepare a laminated sheet of alumina fibers. To this laminated sheet, a needling process was performed using a needle board having 500/100 cm 2 needles. Then, the obtained sheet | seat material 24 was continuously baked from normal temperature to the maximum temperature of 1250 degreeC, and the sheet | seat material 24 of the alumina fiber of weight 1160g / cm <2> was obtained. The average diameter of the alumina fibers was 7.2 μm, and the minimum diameter was 3.2 μm. In addition, the thickness of the sheet | seat material 24 was 9 mm.

In addition, the average diameter of the fiber was measured by the following method. First, alumina fibers are placed in a cylinder and pressure-pulverized to 20.6 MPa. Next, this sample is placed on a sieve, and the sample which has passed through the sieve is used as a test specimen for electron microscope observation. After depositing gold etc. on the surface of this test body, the electron microscope photograph of about 1500x magnification is taken. The diameter of at least 40 fibers was measured from the obtained photograph. This operation was repeated for five samples to make the average of the measured values the average diameter of the fibers.

[Cutting of sheet material]

The sheet member 24 produced in the above process was cut to have dimensions of 1270 mm long and 1280 mm wide.

[Organic binder impregnation]

The cut sheet material 24 was impregnated with an organic binder. An acrylic resin aqueous dispersion (L x 803 manufactured by Nippon Zeon Co .; 50 ± 10% solids concentration, pH 5.5 to 7.0) was prepared so that the resin concentration was in the range of 1.0 to 10.0 wt%, to obtain an impregnation liquid. Then, this impregnation liquid was impregnated into the sheet | seat material 24 by spray application.

[Suction of solids]

Since the solid content exceeding a predetermined amount adheres to the sheet | seat material 24 after impregnating an organic binder, the excess solid content was removed by the suction process of solid matter (about 3 second). After this treatment, as a result of confirmation by the weighing method, the impregnation rate of the organic binder of the sheet member 24 was 10 wt%.

[Heat compression drying process]

The heat compression drying treatment is performed at a drying temperature of 95 to 155 占 폚 using the sheet member 24 after the suction process. As a result, the average thickness of the sheet member 24 is about 8 mm. Moreover, in this process, the uneven | corrugated height of the upper and lower jig | tool which sandwiches the sheet | seat material 24 was changed, and the sheet | seat material 24 from which the uneven | corrugated height differs in both surfaces was produced. That is, the upper and lower jig used patterns of all waveforms, and the upper pattern had an uneven height of 850 µm, and the lower pattern had an uneven height of 500 µm. Thus, after compression drying, a mat-shaped sheet (that is, uneven height H = 1.7 with respect to uneven height) of 850 µm in the upper surface and 500 µm in the lower surface of the lower surface was obtained (refer to Example 1).

Next, Example 2, 3, 5-7, and Comparative Examples 1 thru | or the same process as the above-mentioned process except having changed the upper and lower jig which sandwiches the sheet | seat material 24 between heating compression drying processes. The sheet member 24 of 3 was produced. In these Examples and Comparative Examples, the uneven height of any one surface or both surfaces of the sheet member 24 is different from that of Example 1, but other manufacturing conditions are the same as those of the sheet member 24 of Example 1. In addition, although Example 4 is the uneven | corrugated height of the same surface as Example 3, it differs in the point that the average diameter of the used fiber is 5.7 micrometers. In Table 1, the fiber diameter used for the sheet | seat material 24 of each Example and the comparative example, the uneven | corrugated height of 1st and 2nd surface, and its ratio are shown.

Average fiber diameter μm Uneven height of the first surface μm Height of unevenness of the second surface μm Rain of uneven height- Number of wrinkles at the time of winding X length mm Drawing load N Judgment Example 1 7.2 850 500 1.7 3 555 ◎ Example 2 7.2 850 700 1.2 4 521 ◎ Example 3 7.2 2550 90 28.3 6 412 ◎ Example 4 5.7 2550 90 28.3 6 453 ◎ Example 5 7.2 2550 80 31.9 7 376 ○ Example 6 7.2 2550 55 46.4 8 312 ○ Example 7 7.2 2550 45 56.7 10 225 ○ Comparative Example 1 7.2 680 850 0.8 20 137 × Comparative Example 2 7.2 850 850 1.0 18 162 × Comparative Example 3 7.2 120 120 1.0 15 148 ×

In addition, the uneven | corrugated height of the sheet | seat material 24 was performed by observing the cross-sectional shape of the sheet | seat material 24 by an optical microscope as mentioned above. As an example, the cross-sectional shape of the 1st surface and the 2nd surface of the sheet | seat material 24 of Example 1 is shown to FIG. 5A and 5B, respectively.

Then, the obtained sheet | seat material 24 was cut | disconnected to the predetermined shape shown below, and was used for various evaluation tests. In addition, about the drawing load measurement, the influence of the average diameter of the inorganic fiber of a sheet | seat material was also evaluated. The test results will be described below.

[Wrinkle measurement result]

The sheet materials 24 of Examples 1 to 6 and Comparative Examples 1 to 4 described above are wound so that a surface having a small unevenness on the surface is in contact with the exhaust gas processing body 20, and is formed on the inner surface side of the sheet member 24. The number and length of wrinkles produced were evaluated. As the exhaust gas treating body 20, a catalyst carrier having a diameter of 80 mm and a length of 150 mm was used. In addition, the sheet | seat material 24 uses the thing of the maximum length of 290 mm (of which the fitting convex part is about 40 mm), width 80mm which has one fitting convex part in one end of a winding direction, and one fitting concave part in the other end. This was uniformly wound on the catalyst carrier so as to be solid, and fitted at both ends to join.

Table 1 shows the results obtained in Examples 1 to 6 and Comparative Examples 1 to 4, respectively. From this table, regardless of the average fiber diameter, when the uneven height of the first surface of the sheet member 24 is 1.2 to 56.7 times the uneven height of the second surface, the number x lengths of wrinkles occurring in the sheet member 24 It can be seen that the value (mm) becomes smaller.

[Pull-out load measurement results]

The sheet member 24 is wound so that the surface with small uneven | corrugated height of a surface may contact the waste gas processing body 20, and both the integral parts are pressed in the cylindrical metal cell 12 made of SUS304 steel, and it is 24 hours or more. After maintaining in that state, the pull load test by the universal testing machine was performed. As the exhaust gas treating body 20, a catalyst carrier having a diameter of 80 mm and a length of 150 mm was used. As the holding sealing material, a sheet material having a maximum length of 290 mm (of which the fitting convex part is about 40 mm) and a width of 80 mm having a fitting convex portion at one end in the winding direction and a fitting concave portion at the other end was used. It wound up to a delay and fitted both ends together. The inner diameter of the metal cell 12 is 84 mm, the length is 200 mm, and the thickness is 1.5 mm. In addition, it can be said from the experiment results thus far that the holding force of the holding sealer to the exhaust gas treating body is sufficient in practical use when the pulling load exceeds 200N.

The results are shown in Table 1 and FIG. 6. Here, the drawing load means the maximum load when extruding the catalyst carrier pressed into the metal cell 12. As a result, regardless of the average fiber diameter, when the uneven height of the first surface of the sheet member 24 is 1.2 to 56.7 times the uneven height of the second surface, the pulling load of the holding and sealing member 15 is 200N. It turned out that it shows the favorable holding power in excess. In addition, when the uneven | corrugated height of the 1st surface of the sheet | seat material 24 is 1.2-28.3 times the uneven | corrugated height of the 2nd surface, the holding sealing material 15 using this sheet | seat exceeds 400 N, and shows that it shows very favorable holding force. Could know.

7 is a graph of the average diameter of the fibers and the pull load. When the first surface and the second surface are the same uneven height (ratio of uneven height = 1.0), it can be seen that when the average diameter exceeds 6 µm, the pulling load suddenly decreases. In FIG. 7, although the plot at the time of making ratio of the uneven | corrugated height of a 1st surface and a 2nd surface into 28.3 is shown, high drawing load is implement | achieved regardless of average diameter. That is, this also can be said to have a remarkable effect on the improvement of the draw load when the average diameter exceeds 6㎛.

(Industrial availability)

The holding sealing material and the exhaust gas purification device of the present invention can be used for a vehicle exhaust gas purification device and the like.

By using the holding sealer of the present invention in the exhaust gas purifying apparatus, the adhesion of the holding sealer to the exhaust gas treating body is improved. Moreover, the influence of the difference in the circumferential length between the inner surface side and the outer surface side of the holding seal member can be suppressed to a minimum, and an exhaust gas purifying apparatus excellent in gas sealing property and holding property to the exhaust gas treating body can be obtained.

Claims (15)

As a holding sealing material for holding an exhaust gas treating body, The holding seal material is a holding material having a first surface and a second surface and composed of a sheet material made of inorganic fibers, wherein the uneven height of the first surface is higher than the uneven height of the second surface. The method of claim 1, The sheet member is a holding seal member, characterized in that configured by needling the laminated sheet of inorganic fibers (needling). The method according to claim 1 or 2, The sheet member is a holding seal member, characterized in that it contains a binder. The method according to claim 1 or 2, The uneven | corrugated height of the 1st surface of the said sheet | seat material is 1.2-56.7 times the uneven | corrugated height of a 2nd surface, The holding sealing material characterized by the above-mentioned. The method according to claim 1 or 2, The holding sealer, characterized in that the average diameter of the inorganic fiber is 6㎛ or more. The method according to claim 1 or 2, The inorganic fiber is a holding seal material, characterized in that the mixture of alumina and silica. The method according to claim 1 or 2, And said exhaust gas treating body is a catalyst carrier or an exhaust gas filter. The method according to claim 1 or 2, The holding seal member is wound around at least a portion of an outer circumferential surface of the exhaust gas treating body except for an opening surface thereof, and the holding seal member is fixed to contact the outer circumferential surface of the exhaust gas treating body. An exhaust gas treatment body, A metal cell accommodating the exhaust gas treating body; An exhaust gas purifying apparatus comprising a holding sealing material wound around at least a portion of an outer circumferential surface of the exhaust gas treating body except for an opening surface thereof, The holding seal member is made of a sheet material having a first surface and a second surface, which is made of inorganic fibers, and the uneven height of the first surface of the sheet material is higher than the uneven height of the second surface, and the second surface of the sheet material is An exhaust gas purifying apparatus, wherein the exhaust gas purifying apparatus is wound and fixed to contact an outer peripheral surface of the exhaust gas treating body. The method of claim 9, The sheet material is an exhaust gas purification device, characterized in that configured by needling the laminated sheet of inorganic fibers. The method according to claim 9 or 10, And the sheet member contains a binder. The method according to claim 9 or 10, The uneven | corrugated height of the 1st surface of the said sheet | seat material is 1.2-56.7 times the uneven | corrugated height of a 2nd surface, The exhaust gas purification apparatus characterized by the above-mentioned. The method according to claim 9 or 10, Exhaust gas purifier, characterized in that the average diameter of the inorganic fiber is 6㎛ or more. The method according to claim 9 or 10, And said inorganic fiber is a mixture of alumina and silica. The method according to claim 9 or 10, The exhaust gas treating body is an exhaust gas purifying apparatus, characterized in that the catalyst carrier or the exhaust gas filter.

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